Motor control and protection

Universal Motor Controller UMC100-FBP

Universal motor controller from ABB
– the intelligent on-site solution.

Large industrial plants often have several thousand motors to provide the required
motion. Any unplanned or sudden motor stops can lead to faults in the process
sequence, which can be very cost intensive. Reliable management of these motors
is therefore essential for ensuring that the production sequence is controlled.

ABB’s new UMC100-FBP offers you the optimal solution. Typical areas of application include:
UMC100-FBP is a flexible, modular and expandable motor –– The oil and gas industry
management system for constant-speed, low-voltage range –– The cement and paper industries
motors. Its most important tasks include motor protection, –– The steel industry
preventing plant standstills and reducing down time. Early –– Mining
information relating to potential motor problems means that –– The chemicals industry
unplanned plant standstills can be avoided. Swift diagnosis –– Water supply and distribution
of the cause of the fault serves to reduce down time. –– Power plant engineering
–– The food and beverage industry

Due to the benefits it provides, the UMC100 is used world-

wide in many segments and in projects with several thousand
motor controllers.

2 2CDC135011B0202
Less time and energy required for planning, design and
materials
The universal and modular structure of the UMC100-FBP is
impressive even during the planning and design stage. The
amount of wiring required is significantly reduced, as all the
necessary protection, monitoring and control functions are
integrated into a single device.
A single version for all current ranges and fieldbuses simplifies
planning, inventory and servicing.
Simple integration in the tightest of spaces
Thanks to its compact design and integrated measurement
system, the UMC100-FBP fits into even the tightest of spaces.
This is a huge advantage, particularly for applications involving
plug-in low-voltage switchgear with limited space or for retro-
fitting existing systems to accommodate a modern motor
management system
Optimally matched
The system's modular expandability enables optimal adaptation
to the application. Even the basic UMC100-FBP device fulfils the
requirements of most applications. All of the control functions
required in the field are integrated and are simple to configure
via parameters. Application-specific control functions can be
realized with the programmable logic system.
In addition to the digital expansion modules, voltage modules
are now available to measure the three-phase voltages. They
extend the UMC100 to include functions such as overvoltage/
undervoltage protection, underload protection, power and
energy.
Electronic motor protection
The UMC100-FBP provides comprehensive, electronic motor
protection. It operates fully independently and ensures that
the motor is protected at all times, even if the control system
or fieldbus fails.
The precise electronic measurement system enables optimal
utilization of the motors. Constant trip behaviour is ensured by
the high long-term stability of the tripping characteristics.
Open communication
The UMC100-FBP is equipped with an interface for connecting
a communication adapter – the FieldBusPlug (FBP).
Selecting the relevant FieldBusPlug enables the motor controller
to communicate using the widespread standard fieldbuses
Profibus DP, DeviceNet, Modbus or CANopen.
UMC100-FBP can also be used without communication as a
stand-alone with full functionality.
HIgh plant availability
The UMC100-FBP continuously transmits comprehensive
operational, service and diagnostic data from the motor to the
control system. This means that faults can be detected early
on and can be avoided by suitable measures, or their effects
can be limited. This increases the plant's availability.
Rapid fault detection and rectification
A comprehensive diagnostic system facilitates fault localization
and rectification in the event of a fault. This means that down-
time can be reduced to a minimum.
2CDC135011B0202 3
UMC100-FBP

The highlights
–– Compact housing with integrated measuring system
–– Overload protection for nominal motor currents up to 850 A
–– Integrated thermistor motor protection
–– Integrated ground fault protection
–– Up to 14 digital inputs and 9 outputs
–– Voltage measurement up to 690 V
–– Power factor (cos j), energy
–– Flexible communication via all fieldbuses
–– PROFIBUS DP
–– DeviceNet
–– Modbus RTU
–– CANopen
–– Worldwide approvals

4 2CDC135011B0202
Main areas of application

Due to the benefits it provides, the UMC 100 is used Water supply and treatment
worldwide in many segments and and projects –– Pump controls as required
–– Underload detection
Cement factories –– Cos j
– – Robust and compact design – – Pump cleaning application
–– Several inputs, e.g. for querying the position of the damper
limit switches Mining
– – Rated motor voltage of up to 1000 V
The oil and gas industry, chemicals – – Can be used at altitudes of up to 5000 m
–– Programmability (goldmines in Peru)
–– Ground fault monitoring – – Ground fault monitoring
–– Undervoltage detection and configurable restart following
voltage restart
–– Protection of motors in hazardous environments (ATEX)
–– Use in IT networks

2CDC135011B0202 5
A modular system to suit all requirements

Application
1 1 Short-circuit protection
2 Contactor
3 Control panel
4 Universal Motor Controller
5 Expansion module DX111/122
6 Voltage module VI150/VI155
7 Signal units
2 8 Command elements
7 9 Motor
10 C ommunication adaptor

(FieldBusPlug)

5 6
4
3

10

With a single basic unit and perfectly coordinated accessories, the UMC 100 meets
all the requirements that are relevant in the area of motor management

A single UMC100-FBP basic unit for all motor currents and
fieldbus systems simplifies planning, construction and inventory.
The UMC100-FBP basic unit meets all the key requirements
with regard to motor protection and control.
Further requirements for functionality in complex applications
are met via the simple expandability of the UMC100-FBP – for
example, more I/Os for additional process signals, further
protection and monitoring functions through motor voltage
measurement.

–– Compact design with integrated current transformer

–– 6 inputs and 4 outputs – enough for all starter functions
that occur in practice
– – PTC input
– – Integrated motor starter functions
– – Additional programmability
– – Flexible communication via all common fieldbus systems

6 2CDC135011B0202
Easy expandability

More functionality with complete flexibility

Digital modules DX111 / DX122

– – These compact modules increase the number of inputs and
outputs of the basic unit
–– Inputs for 24 V DC and 110/230 V AC
–– Additional analog output for instrument

Voltage modules VI150/VI155

–– Extension modules for 3-phase voltage measurements up
to 690 V in grounded and ungrounded networks
–– Extend UMC100 to include functions such as undervoltage/
overvoltage protection, underload protection, power factor,
power and energy. Measurement of the total harmonic
distortion (THD)

UMC100-Pan control panel

–– Display of measured values, status and diagnosis
–– Operation
–– Access to all parameters
–– Choice of 7 languages
–– Upload/download parameters (save)

CEM11 ground fault detection

–– As an alternative to the ground fault monitoring that is inte-
grated in the basic unit, CEM11 also allows lower ground
fault currents to be monitored and enables use in networks
with high impedance

2CDC135011B0202 7
The functions in detail

The UMC100-FBP in detail

Motor protection Motor control

–– The UMC100-FBP provides comprehensive motor protection –– Integration of the most important motor control functions
for three-phase AC motors as ready, easily parametrizable blocks
– – Overload protection with adjustable tripping class 5E, 10E, –– Direct, reversing, star-delta starters
20E, 30E, 40E in accordance with EN/IEC 60947-4-1 –– Pole reversal/Dahlander pole-changing
– – Locked rotor protection –– Actuator
– – Phase failure detection –– Inching
– – Asymmetry detection –– Adjustable restart strategy (load shedding)
– – Phase sequence detection
– – Undercurrent/overcurrent protection Extended motor control
– – Thermistor motor protection with PTC –– Freely programmable for special, application-specific
– – Ground leakage detection – internally or using CEM11-FBP control functions
sensor – – Simple adaptation to specified control functions
– – Limitation of the motor starts per time unit – – Comprehensive library
– – Rated motor current 240 mA to 63 A with a single version, – – Blocks for logic, counters, timing
no accessories required – – Access to all I/Os and internal signals
–– Rated motor current > 63 A with external current transformer
–– Independent motor protection, fully operational even without Control stations
bus connection – – Individual configuration of control points
– – Operation via DCS
In combination with voltage module VI150/VI155 – – Local control
–– Undervoltage/overvoltage protection – – Control panel
–– Power supervision
–– Power factor supervision (cos j)
–– Voltage-based detection of phase failure, asymmetry and
sequence

8 2CDC135011B0202
Motor status/communication Open communication
Quick and comprehensive access to all data via control UMC100-FBP is a fieldbus-neutral basic device; the
station, fieldbus and/or laptop FieldBusPlug communication adapter means that the
fieldbus system is freely selectable.
Operating data
– – Motor status
–– Motor current
–– Thermal load
–– Maximum starting current
–– Run-up time
–– Time to trip
–– Remaining cool down time
Modbus®
Operating data with voltage module VI150/VI155
–– Phase voltages
–– Active power
–– Apparent power
–– Power factor
–– Energy

Service data
–– Counter for motor operating hours
–– Number of starts
–– Number of overload trips

Diagnostic data
–– Comprehensive and detailed error messages and warnings
–– Log for previous 16 errors
–– Plain text display on the control panel

2CDC135011B0202 9
 Withdrawable applications

Verbindung zum
Einschub
Serielle
Verbindung zum vom
Einschub vorherigen
FieldBusPlug
Erdung des Erdung des
Schirmes
Schirmes

zu UMC 1- 4
CDP12-FBP (4 x CDP16-FBP)
vom
vorherigen
FieldBusPlug

FieldBusPlug
(z. B. PDP22-FBP)

Passivkabel zum
innen: nächsten
CDP13-FBP FieldBusPlug PDQ22-FBP
Passivstecker -
zum
Haltewinkel
CDP11-FBP nächsten
FieldBusPlug
Universal Motor Controller Kabelraum Kabelraum (PDX11-FBP)
(z. B. UMC22-FBP)

The UMC100-FBP is ideally suited for plug-in applications in The PDQ22-FBP version is available for applications with
Motor Control Centers. Here, the UMC100-FBP is positioned Profibus DP, in addition to the standard PDP22-FBP fieldbus
within the slot while the FieldBusPlug fieldbus connection is connector. This offers the option of connecting up to four
mounted externally. Communication is undertaken by means UMC100s to a Profibus DP node. This can be especially
of a simple serial link. economical for devices which are aligned near each other.
The connection between the PDQ22-FBP and the connected
This separation results in the following advantages: devices is realized with commercially available connection
–– Fieldbus communication is undertaken directly from slave cables.
to slave without drop lines
–– M aximum fieldbus performance and baud rate is guaranteed –– All devices connected to a node can be configured and
– without the need for special adaptation maintained independently from each other.
–– If one of the drawers is removed, the fieldbus slave continues –– Status indication for communication and each connected
to operate device
– – A ccidental exchange of the plug-in modules is detected –– The saving of slave addresses on the fieldbus
and signaled to the control system –– Reduction of infrastructure costs due to reduction of the
number of slaves, i.e. more motors per fieldbus master,
fewer repeaters

Retrofit
Due to its compact dimensions with an integrated measurement –– Programmable logic for optimal adaptation to the existing
system, the UMC100 is extremely well-suited for updating and control concept
modernizing existing switchgear. –– Inputs for various voltages AC/DC
–– Control of any existing instruments
–– Optionally with or without communication via fieldbus

10 2CDC135011B0202
Safe disconnection of motors

The requirements for safety-oriented applications are gaining
increasing importance in process automation. For example, due
to new regulations and specifications, the safe disconnection
of motors for the protection of people, the machine, and the
environment is becoming more and more important.
The UMC100, together with the flexible RT9 safety relay from
ABB, meets these requirements and complies with standards
EN 62061:2005 and EN ISO 13849-1:2008 for functional
safety up to SIL 3 and PL e. The emergency stop signal
can come from either a separate safety system or from an
emergency stop switch on site.
–– Coordinated operating and safety functions
–– Message texts on the control panel enable rapid diagnosis
on site
–– Clear diagnostic message to the process control system

Process control system Safety system Process control system

L1/L2/L3 L1/L2/L3

Pressed

Command Command
Monitoring Monitoring ABB emergency
Diagnostic data Diagnostic data stop
Switch off Switch off Inca1 push button
K1
Switch off Switch off
Fieldbus Contactor control Fieldbus Contactor control
– PROFIBUS voltage for K2 – PROFIBUS voltage
– DeviceNet – DeviceNet
Feed- Emer- Feed- Emer-
– Modbus – Modbus
back gency back gency
– CANOpen – CANOpen
signal stop signal stop

Safety Safety
relay RT9 relay RT9
Operational Operational
switching K2 switching

2CDC135011B0202 11
Parameter assignment and programming

Parametric assignment Programming

For most applications it is sufficient to select and parametrically
assign one of the UMC100's standard integrated control
functions. This is realized independently from the applicable
control system and fieldbus system by means of GSD and
EDS configuration files or even more conveniently via a DTM
device (DTM/FDT technology). All of the parameters can be
configured via the control station.
Asset Vision Basic and DTM
ABB Asset Vision Basic as FDT frame application, together
with the DTM (Device Type Manager) are comprehensive tools
for straightforward parameter assignment and programming
of the UMC100 as well as all devices equipped with DTM. It
enables creation of configurations, up/downloading, reading
out of diagnostic data, and - if configured - even control of
the UMC100 - either centrally via the control system, via the
fieldbus or directly on-site at the switching cabinet.
For special applications, it is possible to create an optimally
adapted control function with the help of the editor integrated
into the DTM. A comprehensive library of function blocks is
available to you for this purpose. It is possible to access all of
the existing variables in the UMC100 and the expansion
modules. Comments can be inserted as required.
All of the control functions integrated into the UMC100 are
available as templates and can be very easily adapted to
requirements. It is possible to create your own library of
special control functions by means of importing / exporting
these templates.

The clear interface facilitates simple configuration of all

parameters and error texts required for the control station.
In doing so, the graphical display supports you with prompts
and by checking the data.

12 2CDC135011B0202
Diagnostics and operation

Diagnostics and maintenance Operation

Comprehensive and clear diagnostics help to avoid faults and The DTM can also be used to operate the motor if it is
make it possible to rectify them quickly in the event of errors. configured to do so.

Quick display of all data: –– Start forwards/backwards

– – Operating data –– Stop
–– Motor status and current, thermal load –– Error reset
–– Status of all I/O signals
– – Diagnostic data In addition, the most important operating data are displayed
–– Errors, warnings in the same window
– – Service data
–– Operation hours
–– Number of starts
–– Number of overload trips

The display of control signals facilitates diagnosis during

commissioning.

It speaks your language

The control panel enables the display of all data on-site. Errors
and warnings are displayed as clear text in the configured
language. Individual texts can be assigned to external errors.

2CDC135011B0202 13
UMC100 system overview

Basic device UMC100-FBP

Main power
Voltage max 1000 V AC
Frequency 45…65 Hz
Rated motor current 0.24…63 A, without accessories
Greater currents with external transformer
Tripping classes 5E, 10E, 20E, 30E, 40E in accordance with EN/IEC 60947-4-1
Short-circuit protection Separate fuse on network side
Control unit
Supply voltage 24 V DC
Inputs 6 digital inputs 24 V DC
1 PTC input
Outputs 3 digital relay outputs
1 digital transistor output
Interfaces 1 for ABB FieldBusPlug
1 for UMC100-PAN control station
1 for expansion module

Expansion modules
The UMC100 can be expanded to include digital expansion module DX111 or DX122 and voltage module VI150
or VI155. Communication takes place via a simple two-wire line. The maximum distance allowed between the
UMC100 and the expansion module is 3 m.

Digital expansion modules DX111 / DX122

Expands the UMC100 to include additional digital inputs and outputs and an analog output
Supply voltage 24 V DC
Inputs DX111 8 digital inputs 24 V DC
DX122 8 digital inputs 110/230 V AC
Outputs 4 digital relay outputs
1 analog output, 0/4…20 mA, / 0…10 V configurable

Voltage modules VI150/VI155

Voltage modules for determining phase voltages, power factor (cos j), active power, apparent power, energy,
harmonic content (THD)
VI150 for use in grounded networks
VI155 for use in grounded and ungrounded networks

Supply voltage 24 V DC
Voltage inputs L1, L2, L3
Rated voltage range 150 … 690 V AC
Outputs 1 digital relay output

14 2CDC135011B0202
UMC100-PAN control panel
Installation on the device or on the switching cabinet door
Graphics-enabled and backlit display, 3 LEDs for status indication
Freely configurable error messages
Multilingual: German, English, French, Italian, Portuguese, Spanish, Russian

Current transformer KORC

Only required for rated motor currents >63 A
Linear transformer, 3-phase with terminal block, designed for connecting leads Cu 2.5 mm2

CEM11 earth leakage sensors

Summation current transformer for connecting to a digital input
Mounting with bracket on DIN busbar or wall
Models
CEM11-FBP.20 80 – 1,700 mA 20 mm Ø
CEM11-FBP.35 100 – 3,400 mA 35 mm Ø
CEM11-FBP.60 120 – 6,800 mA 60 mm Ø
CEM11-FBP.120 300 – 13,600 mA 120 mm Ø

Fieldbus connector FBP

For communication with fieldbus systems, supply with 24 V DC via fieldbus cable
Installation on the UMC100; for plug-in systems, the fieldbus connector is mounted externally

Assembled connectors with various cable lengths. M12 connection technology for reliable contacting
Extensive range of accessories available
Models
PDP22-FBP Profibus DP V0/V1
DNP21-FBP Devicenet
MRP21-FBP Modbus RTU
COP21-FBP CANopen
PDQ22-FBP Profibus DP V0/V1 (for the connection of 1 to 4 UMC100s)

2CDC135011B0202 15
Contact us
ABB STOTZ-KONTAKT GmbH
Eppelheimer Straße 82
69123 Heidelberg, Germany
Phone: +49 62 21 / 701-0
Fax: +49 62 21 / 701-1325
Email: info.desto@de.abb.com
www.abb.com
Note:
Brochure number 2CDC 135 011 B0202 printed in Germany (01/12-3.5-VCM)
We reserve the right to make technical changes or
modify the contents of this document without prior
notice. With regard to purchase orders, the agreed
particulars shall prevail. ABB AG does not accept
any responsibility whatsoever for potential errors or
possible lack of information in this document.
We reserve all rights in this document and in the
subject matter and illustrations contained therein.
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